Custom Mobile Battery Boxes & Mobile Battery Packaging
Batteries and power banks are the one product category where the carton has a legal job on top of a selling job. Get the marking wrong and the shipment sits at customs, or a retailer refuses the pallet. We print a lot of mobile battery packaging at ZEE Packaging and this is where most brands need help.
The Marking You Cannot Get Wrong
Lithium cells are regulated freight, so the mobile battery box carries more mandatory information than most electronics.
- UN3480 or UN3481 marking depending on whether the cell ships alone or with equipment
- Lithium battery handling label where required
- Watt hour rating, this one gets checked constantly
- mAh capacity, printed large because buyers compare on it
- Voltage and output specification
- CE, FCC, UKCA, RoHS and WEEE bin symbol
- Do not incinerate and disposal instructions
We always advise clients to confirm current requirements with their freight forwarder, because the rules move. What we do is make sure everything you supply lands correctly on the dieline.
What Sells On The Front
- Capacity in mAh, biggest element on the mobile battery box
- Output wattage and fast charge standard, PD, QC, or similar
- Port count and type, USB C and USB A
- Number of full phone charges, buyers understand this better than mAh
- Device compatibility
- Tuck end folding carton the everyday retail mobile battery box
- Rigid lid and base premium mobile battery packaging for flagship ranges
- Drawer slide nice reveal, popular on higher price points
- Corrugated mailer ecommerce orders going direct
- Window carton shows the unit finish on shelf
- Blister backer card for peg display in accessory aisles
Sizes We Run Often
Every mobile battery box is built to your unit, though these come up regularly:
- 4" x 3" x 1" for a slim 5000mAh unit
- 5" x 3" x 1.5" for 10000mAh, our most common mobile battery box
- 6" x 3.5" x 2" for 20000mAh
- 7" x 5" x 2" for a kit with cable and pouch
- 8" x 6" x 2.5" for larger capacity or laptop capable bank
Send the unit dimensions plus every accessory going in and we build the dieline around the full kit.
Board And Insert
Power banks have real weight for their size, so thin board fails here.
- SBS C1S for printed retail mobile battery box
- Corrugated E flute when it ships on its own
- B flute for multipacks and heavier capacities
- Rigid greyboard 36pt or 48pt for premium ranges
- Cardstock 18pt to 24pt minimum, we would not go thinner
Inside we run die cut paperboard cradle, foam bed and molded pulp. A snug well stops the unit sliding, because a heavy bank moving inside a box will burst a flap open in transit.
Finishing
- Soft touch lamination on premium mobile battery packaging
- Matte film, it hides finger marks better than gloss
- Spot UV over the logo or capacity figure
- Foil stamping, silver and gunmetal suit this category
- Blind deboss for a quiet premium look
- Printed interior, gets filmed in unboxing
Greener Options
- Recycled kraft mobile battery box with no lamination
- Molded pulp cradle instead of foam
- FSC certified board, certificate on request
- Soy based ink
- Right sized mobile battery packaging so you ship less air
How We Work
- 100 unit minimum on any mobile battery box design
- Free 3D mockup and flat proof
- Free dieline from our inhouse designer
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
Do you add the UN marking for us?
We print what you supply and we place it correctly on the dieline. We do not decide which marking applies to your cell, your freight forwarder or compliance team confirms that.
Which board for a 20000mAh unit?
20pt minimum on folding carton, or corrugated E flute if it ships alone. That weight will bow a thin base panel fast.
What is the price of a mobile battery box?
Rough estimate is $0.50 to $1.30 per unit for folding carton, $1.10 to $2.70 for corrugated mailer and $2.50 to $6.50 for rigid at moderate quantities. Foam inserts, foil and window patches push it up. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Can you fit cable, pouch and bank in one box?
Yes, a multi cavity cradle so each item sits in its own well and nothing knocks together.
Is a window a good idea here?
On shelf it helps, because buyers want to see the finish and port layout. Online it adds cost for little return.
Do you print watt hour as well as mAh?
Yes, and we recommend both. Watt hour is what carriers check, mAh is what shoppers compare.
Will the box survive courier on its own?
A rigid box wont without an outer. For direct shipping we move you to a corrugated mailer or a shipper around the retail carton.
